Low Cost Mobile Power Generator System.

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LOW COST MOBILE POWER GENERATOR SYSTEM

CHANG BOON HAI

This report is submitted partial fulfillment of the requirement for the award of Bachelor of Electronic Engineering (Industrial Electronics/ Telecommunication Electronics/

Computer Engineering*) With Honours

Faculty of Electronic and Computer Engineering Universiti Teknikal Malaysia Melaka (UTEM)

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ii UNIVERSTI TEKNIKAL MALAYSIA MELAKA

FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER BORANG PENGESAHAN STATUS LAPORAN

PROJEK SARJANA MUDA II

Tajuk Projek : LOW COST MOBILE POWER GENERATOR SYSTEM

Sesi Pengajian: 2010/ 2011

Saya ………...CHANG BOON HAI………

(HURUF BESAR)

mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syarat- syarat kegunaan seperti berikut:

1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. Sila tandakan ( √ ) :

(Mengandungi maklumat yang berdarjah keselamatan atau SULIT*

TERHAD*

TIDAK TERHAD

________________________________

(TANDATANGAN PENULIS)

Alamat Tetap: LOT 300, JALAN LOPENG, KAMPUNG LOPENG, 98000, MIRI, SARAWAK.

Tarikh: 3 MEI 2011

kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat terhad yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Disahkan oleh:

___________________________________

(COP DAN TANDATANGAN PENYELIA)

Tarikh: 3 MEI 2011

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iii

“I hereby declare that this report is the result of my own except for quotes as cited in the references”

Signature : ………

Author : CHANG BOON HAI

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“I hereby declare that i have read this report and in my opinion this report is sufficient in terms of the scope and quality for the award of Bachelor of Electronic

Engineering (Industrial Electronics/ Telecommunication Electronics/Computer Engineering*) with Honours”.

Signature : ………..

Supervisor Name : MR. DAVID YAP FOOK WENG

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ACKNOWLEDGEMENT

First and for most, a sincere gratitude goes to my supervisor Mr. David Yap Fook Weng for his guidance and supervision for completing my final year project through out these two semesters as a final year student. Under his supervision and ideas, the project went on smoother without delay.

Besides my supervisor, I would also like to thank my family, especially my parents and brothers as they have given me spiritual and financial support for any difficulties that I have encountered. For them, love is always at heart even distances away.

Next I would say thanks again to the friends that have played such an important role when I needed help in doing my project. They have sacrificed their energy and time to help without hoping for anything in return. Finally, I would like to thank the faculty itself for providing all aspects of help and facilities that has made me a competent student of Universiti Teknikal Malaysia Melaka (UTeM).

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ABSTRACT

The aim of this project was to build a low cost mobile power generator system that can be portable for outdoor used where electricity is hard to access. Alternative energy is always around us such as wind, sun and hydro. These energies are clean and renewable. Power is a main issue that concerns many countries especially for the undeveloped rural areas. In order to harness free and clean energy, solar power is the ideal choice since the sun’s intensity is constant through out the year. The conventional solar panels are placed at a static position and then collect the energy from the sun. This causes power to be loss when the panel is not perpendicular to the sun’s incident ray. And as the angle of incident deviates greater, so will be the energy loss. Hence a smart way to solve the problem is by tracking the sun’s movement all day long. The best way to track the sun is using a dual axis solar tracker which is more efficient compared to single axis solar tracker. The dual axis that is build is a prototype that is only to support a light solar panel. The motor that is rotating and tilting is the servo motor that can be controlled easily by a PIC microcontroller. Four LDRs are then used to detect the sun’s position that will trigger the movement of the servo motor to move the panel to track the sun’s position. The design is then tested to see how smart it tracks the difference of light detected by the LDR and how the servos move to the correct position. The result and analysis will then be presented in the report.

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ABSTRAK

Tujuan projek ini adalah membina sebuah penjana kuasa yang berkos rendah dan boleh dibawa untuk aktiviti-aktiviti luar yang sukar untuk mendapat sumber elektrik. Tenaga alternatif sentiasa wujud di sekeliling kita seperti angin, matahari dan hydro. Tenaga-tenaga ini adalah bersih serta boleh diperbaharui. Issue tenaga pada zaman ini adalah isu telah menjadi perhatian pada negara-negara di seluruh dunia terutamanya kawasan yang belum dibangunkan. Tenaga solar adalah menjadi pilihan utama untuk dimanfaatkan kerana negara kita mempunyai pancaran matahari yang berpanjangan pada seluruh tahun. Cara tradisi untuk meletak panel suria adalah pada suatu kedudukan yang statik. Kebanyakan tenaga akan hilang sebab semasa posisi panel suria adalah tidak 90 darjah tegak pada pancaran matahari. Semakin besar darjah yang tidak tegak 90 darjah dari pancaran matahari, semakin besar kehilangan tenaga dari panel suria. Cara untuk mengatasi masalah ini adalah dengan mengunakan penjejak matahari yang mempunyai dua paksi untuk menjejak posisi matahari sepanjang hari. Cara ini adalah lebih berkesan berbanding penjejak yang hanya satu paksi. Penjejak matahari dua paksi adalah merupakan prototaip yang hanya dapat menyokong panel suria yang ringan. Moto yang akan memusing dan mencondong panel suria tersebut adalah servo moto yang boleh dikawal oleh PIC yang boleh disambung terus dari servo moto. Empat LDR akan digunakan untuk mengesan kedudukan matahari dan mengaktifkan servo moto untuk bergerak. Prototaip tersebut akan diuji apabila sudah siap dan cara mengesan kedudukan matahari oleh prototaip akan diperhati. Segala keputusan dan analisis hasil projek kemudian akan dipaparkan dalam laporan ini.

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CONTENTS

CHAPTER CONTENT PAGE

PROJECT TITLE i

RECOGNITION ii

ACKNOWLEDGEMENT v

ABSTRACT vi

ABSTAK vii

CONTENTS viii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF ABBREVIATIONS xiii

I INTRODUCTION

1.1 Introduction to Project 1

1.2 Objectives 2

1.3 Problem Statement 3

1.4 Scope 3

1.5 Methodology 4

1.5.1 Methodology Flow Chart 5

1.6 PSM Report Overview 6

II LITERATURE REVIEW

2.1 Low Cost Mobile Power Generator System 7

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2.2.1 Solar Power Projects for Rural Areas 8 2.3 The Theory of the Solar Cell 10 2.3.1 Efficiency 12

2.4 Charge Controllers 12

2.5 DC to AC Inverters 13

2.6 Storage Battery 14

2.7 Solar Batteries 15

2.8 Maximizing Power of Solar Panel through

Solar Tracking 16

2.9 Sun Tracking Method 18

2.10 Light Dependent Resistors 19 2.11 Solar Tracking Sensor Methodology 20

2.12 Motors 22

2.12.1 DC Motor 22 2.12.2 Stepper Motor 22 2.12.3 Servo Motors 23

2.13 PIC 16F877A 25

2.14 LM 7805 26

III METHODOLOGY

3.1 Methodology 28

3.2 Main Components 29

3.2.1 Solar Panel 30 3.2.2 Charge Controller/ Battery Chargers 31 3.2.3 Storage Battery 32 3.2.4 DC to AC Inverter 32 3.3 Design of the Dual Axis Solar Tracker 34 3.3.1 Solar Tracker Free Movement 35 3.3.2 Materials for Dual Axis Solar Tracker

Design 35

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3.3.4 Light Dependent Resistors as Solar Tracking Sensors

3.3.5 Servo Motors 38 3.3.5.1 Servo Motor Movement 40 3.3.6 LM7805 and LM7806 voltage regulator 42 3.3.7 PIC 16F877A Microcontroller 43 3.3.8 PIC C Compiler Programming Language 45 3.3.9 PIC Kit 2 Programmer 45 3.3.9.1 PIC Microcontroller

Program Download Process

3.4 Tracking Algorithm 48

3.4.1 Flow Chart of Tracking Algorithm 51

IV RESULT AND DISCUSSIONS

4.1 Result 52

4.2 Solar Power Generator System 52 4.3 Costs for the Low Cost Mobile Power Generator

System

4.4 Result of Dual Axis Solar Tracker Tracking 54 4.5 Mechanical Design of the Solar Tracker 58 4.6 ADC Voltage Conversion 59 4.7 RC Servo Motor PWM Control 59

4.8 Hardware Overview 60

4.9 Discussions 63

V CONCLUSIONS AND RECOMENDATION

5.1 Conclusion 65

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REFERENCES 68

APPENDIXES 71

APPENDIX A: Dual Axis Solar Tracker Coding 69 APPENDIX B:16F87XA Data Sheet 75 APPENDIX C: LM78XX/LM78XXA Data Sheet 79

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xiii

LIST OF TABLES

NO TITLE PAGE

2.1 The relationship of current with different angle of incidence on a solar panel.

3.1 Specifications of the 20W mono crystalline solar panel 30 3.2 The common appliance used in the house and power

consumption in watts.

3.3 The specification of the RC servo motors 40 4.1 The components and the cost for the power generator

system.

4.2 The resistance measured at different times of a day. 55 4.3 The servo movement based on voltage drop of R2 from

north and south sensor.

4.4 The servo movement based on voltage drop of R2 from east and west sensor.

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xiv

LIST OF FIGURES

NO TITLE PAGE

1.1 The flow chart of methodology 5

2.1 The installation process of the solar panel at the Long Makabar Cultural Centre.

2.2 The solar panel that has been installed on the cultural center. 10 2.3 The PV principle diagram when exposed to sunlight. 11 2.4 The equivalent circuit for the solar cell. 12 2.5 The differences of square, modified and pure sine wave outputs

from the inverter.

2.6 AGM batteries. 15

2.7 Gel batteries. 16

2.8 The plotted graph of the current relationship with different angle of incidence.

2.9 Different types of LDRs available in the market. 20 2.10 The pyramidal shape that is used to locate the sensors for solar

tracking

2.11 The sensors that use an object for blocking sunlight to trigger respond

2.12 DC motor outlook. 23

2.13 A typical stepper motor. 24

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2.15 the pin descriptions of the PIC 16F877A 26

2.17 The LM 7805 illustration. 27

3.1 The flow chart for the methodology to completing the project. 29 3.2 The 10A Gamma solar charge controller. 31 3.3 The NS 40 car battery with 32AH ratings. 32

3.4 The DC to AC 300W inverter. 33

3.5 The two axis tilt (left) and tilt and rotate (right) method. 35 3.6 The main components of the solar tracker with the

corresponding dimensions

3.7 The LDR sensor connection with the 1k resistor. 37 3.8 The C40 RC servo(left) and C50 RC servo(right). 39 3.9 The pulse duration that determines the movement of the servo

motor.

3.10 Contained period for every servo motors with 20ms periodic refresh

3.11 The schematic of LM7805 and LM7806. 42 3.12 The PIC 16f877a microcontroller. 44 3.13 The schematic for the PIC 16F877A. 44

3.14 The USB IC SP PIC Programmer. 46

3.15 The IC SP Programmer socket. 46

3.16 The successful program that has been programmed on the PIC microcontroller.

3.17 The shielding of east-west sensors for tracking the sun 49 3.18 The shielding of north-south sensors for tracking the sun 49 3.19 Flow chart of tracking algorithm. 51 4.1 The rotating servo motor being hold by nails to rotate the base

of the solar tracker.

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4.2 The tilting servo that rotates to tilt the panel with strings attached on the panel.

4.3 The east-west sensor design. 60

4.4 The north-south sensor design. 61

4.5 The allocation of the PIC 16F877A microcontroller and voltage regulators.

4.6 The top view of the dual axis solar tracker prototype. 62 4.7 The side view of the dual axis solar tracker. 62 4.8 The front view of the dual axis solar tracker. 63

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LIST OF ABBREVIATIONS

AC - Alternative Current

ADC - Analogue to Digital Converter AGM - Absorbed Glass Matt

CFL - Compact Fluorescent Lamp CCTV - Closed Circuit Television DC - Direct Current

DOD - Depth of Discharge LCD - Liquid Crystal Display LDR - Light Dependent Resistors PCB - Printed Circuit Board

PIC - Programmable Integrated Circuit PID - Proportional, Integral, Derivative PSM - Projek Sarjana Muda

PV - Photovoltaic

PWM - Pulse Width Modulation RC - Radio Control

SLA - Sealed Lead Acid TV - Television

USB - Universal Serial Bus ZIF - Zero Insert Force

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xviii

LIST OF APPENDIXES

NO TITLE PAGE

A Dual Axis Solar Tracker Coding 69

B 16F87XA Data Sheet 73

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CHAPTER 1

INTRODUCTION

1.1 Introduction to Project

Energy resources have become an importance when we are out for outdoor activities. If it rains, camp fires will die out and torch light batteries usually do not last long. Besides that, hawkers from the night market also rely on generators to provide light.

The world is full of alternative energies such as the heat from the sun, wind and hydro power. These energies can be harness to reduce relying totally on the supplied electricity. Moreover, some of the electrical devices and home lightings use only little power. Harnessing the natural energies can save money paid for the electricity and help to save our world. Hence the purpose of this project is to design a fully automated low cost power generation system that will harness solar energy and then convert it into electrical energy to power some of the electrical devices at home and for outdoor lighting. An additional feature is the solar tracking method of the panel which can maximize the energy harnessed.

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The system will also include a backup battery which will store the extra charge giving the system to provide longer energy supply. The cost for the project will be emphasizing on low cost to produce so that it will be affordable to be installed for every home. Moreover, the design of the low cost mobile power generator will be convenient to be carried around to places where availability for electricity is an issue.

1.2 Objectives

The objective for the project is to produce a mobile generator system which is portable for many various uses such as outdoor activities and areas where there is a shortage of power supply. Besides that, it can also be used for residents in the rural area. The design of the project will also focus on low cost on producing the generator so that it is affordable. The low cost power generation system will be fully automated so that it will be easy to use.

Solar power will be the power source option for the generator. To enhance the design for maximizing energy harness, a dual axis solar tracker will be added on the panel so that tracking the sunlight will improve the charging time.

This project is also meant to fulfil the course requirements of BENU 4973 (Final Year Project I) and BENU 4984 (Final Year Project II). This project will help graduates be more competent in future as the experience gained in completing the project will be highly evaluated by the industry.

The overall objectives can then be summed as the main points below:

i. To build a low cost mobile generator system ii. To have a portable design of the system

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iii. Solar tracking feature to maximize energy harnessed

iv. To complete the course requirement of BENU 4973 (Final Year Project) and BENU 4984 (Final Year Project II).

1.3 Problem Statement

The problems that might surface during the execution with this project can come from various aspects. The project not only involves electronic knowledge but also knowledge for mechanical design for the dual axis solar panel. The pulling forces and torque of the motor must be studied before being purchased so that it will have enough to move the panel.

Another problem will be programming issues for the PIC 16F877A. The complexity of the programming will need to have synchronization with the hardware so that the response is ideal. The programme itself is also very challenging and need to be debugged for errors before downloading it into the PIC. A study on the programming language is essential to complete the task.

1.4 Scope

This project will include working with both hardware and software. The hardware will include the materials such as the solar panel, acid lead battery, PIC microcontroller, stepper motor, printed circuit board (PCB), solar panel and so on. The hardware materials will be purchased either locally or pre order from companies from different states.

Not all of the hardware are designed but rather purchased to contribute as a part of the system such as lead acid battery and charge controller. The hardware will then be set up by connecting the system in a correct sequence. The mechanical design for the

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project will be studied such as the gear ratio that will be needed to move the solar panel to the desired angle.

The available features of the PIC 16F877A will be responsible for controlling the solar panel’s movement. A sensor will be needed to sense the sun’s position so that the panel will then move accordingly into position. The PIC will be functioning as a hub to connect the hardware and software elements in the dual axis solar tracker design.

Studies and research will then be carried on the topics such as the design of the dual axis solar panel. This will include the hardware and software implementation for the system. Software programming and hardware design will be deterministic for the overall outcome of the project.

After the materials are finally ready, the overall components and materials will be combined to work and function as a mobile energy generator. If there are problems that occur, troubleshooting will be done until the project works properly.

1.5 Methodology

To implement the execution of the project, a flow chart will be used to have an overview of the top down approach to construct the project step by step. For any problems that might surface, an iterative method is used to troubleshoot the project until the project can finally function properly. Below is the flow chart that will be used to conduct the project in the methodology.

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1.5.1 Methodology Flow Chart

Figure 1.1: The flow chart of methodology Research/ study on the

requirements of the project Buy materials and electronic

components needed.

Setting up the hardware

Programming

Integration of software and hardware

Testing

Function properly?

End

Troubleshoot Start

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1.6 PSM Report Overview

In brief, the report will contain 5 main chapters that will present the overall progress from the main idea to design and representing the results of the project. At the end, a conclusion will be made based on the findings after the completion of the project. Suggestions will be added along this chapter to provide ideas on how to make the design even better. Hence, the main contents of the report will be as the following:

i. Chapter 1: Introduction ii. Chapter 2: Literature Review iii. Chapter 3: Methodology

iv. Chapter 4: Result And Discussion v. Chapter 5: Conclusion And Discussion

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CHAPTER 1

INTRODUCTION

1.1 Introduction to Project

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1.2 Objectives

The overall objectives can then be summed as the main points below:

i. To build a low cost mobile generator system ii. To have a portable design of the system

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iii. Solar tracking feature to maximize energy harnessed

iv. To complete the course requirement of BENU 4973 (Final Year Project) and BENU 4984 (Final Year Project II).

1.3 Problem Statement

1.4 Scope

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project will be studied such as the gear ratio that will be needed to move the solar panel to the desired angle.

1.5 Methodology

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Figure 1.1: The flow chart of methodology Research/ study on the

requirements of the project

Buy materials and electronic components needed.

Setting up the hardware

Programming

Integration of software and hardware

Testing

Function properly?

End

Troubleshoot Start

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1.6 PSM Report Overview

i. Chapter 1: Introduction ii. Chapter 2: Literature Review iii. Chapter 3: Methodology

iv. Chapter 4: Result And Discussion v. Chapter 5: Conclusion And Discussion

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